Beta-alumina catalysts



Patented Nov. 16,

- UNITED. STATES PATENT OFFICE BETA-ALUMINA CATALYSTS Albert E. Smith and one A. Beech, Berkeley,

Calif., assignors to Shell Development Company, San Francisco, Calif., a corporation of Delaware No Drawing.

. alumina-base catalysts which may be advanta geously employed in various processes. An object of the invention is to provide new and improved catalysts which are less susceptible to loss of activity upon being subjected to relatively high temperatures'and are therefore especiallyadvantageous in processes involving high temperatures, such, for example, as are encountered in periodically regenerating the catalyst by burning car- .bonaceous depositstherefrom. A further object of the invention is to provide new and improved catalysts having improved catalytic'properties. A

further object of the invention is to Drovidea method for the practical production of such catalysta. a The catalysts of the invention alumina. in activated-,(adsorptive) I form either alone or in combination with one or more, cata- I Application December as, 1941, Serial No. 794,080

Claims, (Cl. 252-434) 2 able carriers may be used. A good carrier, however, also has other functions, and of the available carriers, the so=called activated carriers generally give the most active catalysts and are pre-,

ferred. These activated carrier materials, e. 8. activated alumina, activated magnesia, activated zirconia, activated clays, silica gel and activated carbon, are adsorptive, i. e. they are capable of adsorbing water vapor from ordinary air. Activated alumina and silica gel, for example, find wide application in the drying of air and other gases. This ability to adsorb is due to a capillary structure made up largely of extremely fine mi-. cropores affording a large available surface.

Present usage applies the name "micropores to those pores having a calculated radius smaller than 100 Angstroms, and ,macr-opores to those having a radius greater than 100 Angstroms- Further details regarding the pore distribution comprise beta in various microporous adsorptive materials and macroporous non-adsorptivematerials are found in Ind. Eng.Chem. Anal. Ed. 17, 782-791 (1945).

7 Of the' various adsorptive carrier materials available, adsorptive'alumin'a, due'to its marked superiority in certain respects, is aparticularly Lexcellent carriermaterial. This material con-' lytic promoters. They. are prepared according to I the processes of the invention by converting gamma alumina in adsorptive (activated) form to. advsor-ptive beta alumina by, reaction. with certain alkali metal compounds under certainprescribed conditions chosen, toaiford the "conversion to ,betaalumina with a minimum rupture of the 1111- croporous structure of the adsorptive gamma aluj.- mina and, if desired, combining .the adsorptive. (activated) beta aluminaso produced with known catalytic promoters. Y

.In recent yearsgreat progress has been made in the execution of various conversions-by the application of solid catalysts in whichra large number of metals and'metal compoundsas well as a numberof non-metals and compounds of non-metals have received-recognition as suitable catalytic promoters for a, wide-variety 'of reactions. These catalytic promoters can beapplied in combination .withvarious carrier materials, and in general the combination with a suitable carrier material provides a superior catalyst.

A large'number of materials, including such 2 materials as asbestos, chamotte chips, pumice,

I chips of firebrick, kieselguhr and coke, to mention. onlya few, are available as carrier mate- .rials. Since in the simplest case'the carrier material acts to support the promoter and to pro- J vide a larger catalytic surface any or these avail sists of alumina .in the, alpha monohydrate,

and/or gamma form and' is prepared by activating i.-e. carefully dehydrating, certain aluminum hydrates. The micropores are formed throughout the material by theactivation treatment.

The superiority of this adsorptive alumina over -m-ost otheravailable adsorptive carrier materials ,is not only due to itspart-icularly desirablernicroporous structure, but is also 'due in part' to its promoting and stabilizing properties in combination' with a large pore" surface, moderately good thermal stability, availability, and moderate cost;

[The hlthertm'used adsorptive alumina, when- ,used at elevated temperatures as a catalyst per se or as a carrier for one or more supported catalytic promoters in a co'mbinatio'n catalyst graduallydeclinesin catalytic activity. This deactivation of thecatalyst in use may be divided into two components. :One component is a temporary deactivation caused by accumulation of poisons;. 7 this deactivation is easily overcome-by a suitable periodic regeneration treatment e. g. burning on of 'carbonaceous deposits. The other component is a permanent deactivation. In-inost cases this .permanent"deactivation, takes i-place. relatively slowly.= In certaincases, however,-and especially when the catalyst is used in a process 'wherein it is subjected to relatively high temperatures and/or contains certain catalytic promoters, the perma- Gamma AlzOs- Alpha A120: and 7800 Cal.

This transformation takes place at an appreciable rate at temperatures of 900 C.-1100 C. or above. At lower temperatures, such as are commonly employed in catalytic processes, this transformation is very' slow, but may nevertheless take place over an extended period of time. We have furthermore found that many of the catalytic promoters commonly employed with the adsorptive alumina catalyze this transformation and cause it to take place at appreciable rates even at lower temperatures. We have found that the property ofaccelerating the .transformation of gamma alumina to alpha alumina is particularly pronounced in the case of catalytic promoters which are isomorphous with alpha alumina. Thus, the oxides of cobalt, manganese and chromium, for example, are effective in accelerating this transformation. This transformation is also accelerated by acid vapors, such, for example, as vaporsof M003.

We have now prepared new and improved alu- The aluminas of the gamma system of Haber consist of gamma alumina and the hydrated aluminas which upon heating are converted to alpha alumina through the gamma form and are the following:

The alumina alpha trihydrate, known as gibbsite or hydrarglllite. This form is readily prepared synthetically and occurs in nature in the mineral gibbsite and as a component of certain bauxites;

The alumina beta trihydrate, known also as bayerite. It is isomorphous with hydrargilllte. It does not occur naturally, but may be prepared synthetically by proper control of the precipitation conditions;

Gamma alumina. This is-a meta-stable anhydrous oxide which does not occur natuarlly, but may be prepared by carefully controlled dehydration of any of the first three metioned hydrates;

Gelatinous aluminum hydroxide. This frequently encountered alumina is amorphous when freshly precipitated, but after aging the characteristic lines of bohmite can be detected by X-ray analysis. On further aging, the precipitate is gradually transformed to bayerite and finally to hydrargillite;

mina catalysts which retain the desirable prop-- erties of the hitherto-used adsorptive aluminas, but are much more stable. The catalysts of the present invention are prepared with an active, 1. e. microporous, beta alumina. Beta alumina, unlike gamma alumina, is thermodynamically stable and has no tendency to transforminto alpha alumina or any other form upon being ical properties of beta alumina, including its density, refractive index, X-ray diffraction pattern, hardness, .crystal habit, etc., have been determined. The beta alumina formed in fused masses of alpha alumina is not active i. e.,it is in the form of platy crystals having no microporous pregnated with a suitable 'solutionof thedesir'ed alkali metal compound andthen'ilnally-heated Another suitablemethod of combiningfthe alumina [and ature to designate the dihydrate. known that bauxite consists of an extremely finely divided mixture of two or more of the known aluminas and certain argillaceous residues. No dihydrates of aluminas have ever. been observed.

Although we may prepare active beta alumina starting with any ofthe aluminas which pass through the gamma form upon heating to high temperatures, the activated,i. e'. adsorptive, aluminas consisting largely of alumina alpha monohydrate and/or gamma alumina are preferred starting materials since the alkali metal compound can be more thoroughly and intimately contacted with such alumina by various impregnation methods. Thus, when the starting material is in a non-active form itis advantageous to first activate it by a carefuldehydration in the known manner. The material may then be imat the required reaction temperature.

- alkali metal-compound is' tq precipltate the a'lustructure. It contains no water of. constitution I and cannot be activated by any known activation treatment. We have now produced beta alumina in an. active, microporous form. It is this active, microporous beta alumina that is used in the catalysts of the invention.

Active, microporous beta alumina is prepared mine in a solution containing;azsuitable'-amount 7 of alkali and then dehydrating-fthefmixture. If

the alumina, for instance,isprecipitatedwith 3 ammonium hydroxidefrom a solutlon of aluminum nitrate containing the' desired amount of soluble alkali metal compound and the mixture is then evaporated to drynessand heated, the ammonium nitrate is driven .ofL leavin'g the active alumina in intimate mixture with the alkali metal compound. This mixturemmay then be further heated at the desired reaction temperature to produce the active beta alumina. Since all of the applicable aluminas are .converted to gamma alumina before the temperature of reacing the dry mixture at a temperature sufiiciently high to cause reaction-t0 take place, but insufilciently high to destroy the microporous structurepounds of sodium, pota'ssium,'or' rubidium; -Liththe various known forms of alumina into two systezns according-to their behavior upon heating.

tion is reached, the reaction. regardless of the form of the aluminum originally employed, is between gamma alumina 'andflthe'alkali metal compound. r I

The beta alumina may be prepared using comium compounds, when reacted'with the alumina do not form beta alumina. Cesium compounds may react to form a beta alumina; but due to the very large size of the cesium ion the reaction is very slow and difficult to carry out. For commercial application, beta alumina prepared by using compounds of sodium and/or potassium come mainly into consideration. Beta alumina has a characteristic structure giving a characteristic diffraction pattern. See. for example Z. fiir Kristallographie 77, 271 (1931), Z. iiir Kristallographie 97, 59-66 (1937), Z. filr Kristalloaraphie 66, 393-4 (1928), Bur. Stand. J. of Research 8 No. 2, 295-6 (1932). The beta aluminas prepared with the diflerent alkali metals have the characteristic diffraction pattern, but, due to the different ion sizes of the different alkali metals, the characteristic lines are slightly displaced with respect to one another. It is thus convenient when referring to the beta alumina to specify which alkali metal ion is found inthe crystal lattice, Thus, the beta alumina prepared with a sodium compound is designated.sodium beta alumina" and that prepared with a potassium compound is designated potassium beta alumina."

Of the available alkali metal compounds, those which may be converted to the oxide by heating are applicable. Thus, by way of example, the hydroxide, nitrates, bicarbonates, carbonates and acetates may be used.

The alkali metal beta. aluminas have the gen-- eral formula R2O' 11A12O3, in which R represents the alkali metal. On the mo] basis, beta alumina contains 8% moi percent alkali metal oxide. On

, the weight basis it contains 7.7% potassium oxide at a practical rate at temperatures below about 900 C. At higher temperatures, however, the reaction takes place fairly readily. The temperature must not, however, be so high as to sinter or fuse the alumina. Thus, if temperatures above about 1400 C are employed the. micropores of the alumina are destroyed and the material is inactive, i. e. it is not adsorptive. In practice we employ temperatures between 900 C. and 1100 C. and usually between 910 C. and 1050 ,C.

The time allowed for reactions depends upon the temperature employed, the extent or degree of conversion to beta alumina desired, and to some extent upon the amount of alkali metal oxide present and the particular alkali metal em- 36 hours of heating the material shows the charof the alumina to beta alumina. In general, it

is found thatby reacting the alumina; with even one-third to one-half the theoretical 'amountof alkali metal oxide, very stable beta aluminas are formed which are much superior to. gamma alumina and are well suited for usein catalysis.

In such cases the available surface of the alumina is completely converted to the stable'beta alumina and the unreacted gamma alumina is I inaccessible.

i The amount of alkali metal oxide -.reacted with Y the alumina to form the beta alumina depends 'both upon the amount of alkali metal oxide avail-' able'and. the time allowed for: reaction. The

metal compound is employed than it is desired to react, the reacted material contains some unreacted alkali. This unreacted alkali is in most cases undesirable in the flnished'catalyst and .is preferably leached out by treating the beta alumina with a suitable solvent such as water-or dibute acid. It is Darticularlyto be pointed out that the alkali metal oxide which reacts to form the beta alumina is intimately combined as part of the beta alumina structure. It -is not leached out by water or dilute acid, as is any unreacted beta-alumina and'is-preferably somewhat in ex cess of' the stoichiometric amount. In practice we add between 3 and 10 mol and usually between 4 and 8 mol percent of alkali metal compound (calculated as the oxide), to the alumina starting material. 7 Somewhat lesser amounts maybe applied if longer time is allowed'for reactions. If larger amounts such as 1042 mol percent are applied, it is preferable to add only part of the alkali metal compound at first and then to add the remainder after heating for a time to effect partial reaction. Amounts of alkali metal oxide in excess of about 12 mol percent are disadvantageous sired adsorptive properties.

The reaction of the alkali metal compound and the alumina to form the beta alumina is caused r There are a of uncombined alkali (especially of potassium or alkali. j z e few cases in which a small amount rubidium) in the beta aluininais not detrimental.

In" such cases the leaching out of theunreacted alkali can be dispensed with..

The active beta alumina may be formed in the v physical shape of granules or pellets iby preparing it from-a suitablealkali, and granules or pellets of active gamma aluminar Thus; the granular form of active alumina may be used orthe usual non-granular alumina powder may be first formed into pieces of the desired size and shape and then used asthe starting alumina. Also-, if

- it.is desired to employ. the'active beta." alumina in the form :of pellets or other-pressed pieces, it

' is possible 'to first form the active beta alumina to take place b heating-the mixture at a suitable reaction temperature. The reaction takes place slowly by diifusion of the ,alkali' metal oxide into in powder form using'a powdered activealumina as a starting material, and then to subsequently form the active microporous powder into macroporous pieces'by pilling, casting, extrusion'orany of the other methods commonly used to produce porous aggregates from powders. Thus; the active 'beta aluminas of the invention whether or not promoted by one or .more other "catalytic -promoters,'.is suitable for use'in the form of por- 7 =ous aggregates in anxedormovin'g catalyst bed,

or as a fine powder in one of the'so-cjalled powdered" catalyst systems of operation.

- The aluminas' prepared as described-retain the microporous physical structure of 1 the active gamma alumina... However the labile lattice the alumina. The reaction does not takeplace 76 structure: of the active gamma has been transformed to the stabile lattice-structure of beta alumina. The adsorptive ability of the beta alumina produced is somewhat lower than that of the gamma alumina from which it is made due to some growth of the crystallites during the reaction at the high temperatures employed. With proper care to insure intimate contact of the alkali metal with the starting alumina and to avoid overheating during the initial stages of the reaction this loss in adsorptivity may be maintained at a negligible minimum. The available surface area of the beta alumina prepared by the described method is at least 7.5 square meters per gram in any case and nearly always above 20 square meters per gram. Active beta aluminas having available surfaces in the order of 70 to 140 square meters per gram can easily be obtained. From the adsorption isotherms determined by the B. E. T. method (J. Am. Chem. Soc. 60 309 (1938) and applying the currently applied methods (Ind. Eng. Chem. And. Ed. 17, 782-791 (1945)) it is found that the powdered active beta alumina contains a large number of pores in the micropore range, 1. e. having a calculated radius below 100 Angstroms.

Example I Pellets of substantially pure activated gamma alumina were impregnated with an aqueous solution of sodium nitrate to incorporate the equivalent of about NazO. The material was then dried and finally heated to about 1050 C. and held there for about 6 hours. starting material showed the typical X-ray diffraction pattern of gamma alumina. The resulting product was an adsorptive alumina showing the typical X-ray diffraction pattern of sodium beta alumina. The X-ray difiraction pattern showed the presence of some unconverted gamma alumina; none of the lines typical of alpha alumina were found. The small amount of unreacted alkali could be removed by leaching with dilute hydrochloride acid.

The formation of beta alumina through the use of an alkali metal carbonate or bicarbonate appears to proceed through a somewhat more involved mechanism. Thus, the alkali metal carbonate appears first to react with the alumina to produce a surface layer of alkali metal aluminate (R2O-A12O3). The alkali metal oxide then upon continued heating gradually diffuses and reacts with additional alumina to form the beta alumina.

Example II Pellets of substantially pure activated gamma alumina were impregnated with an aqueous solution of sodium carbonate to incorporate about 12% of sodiumcarbonate. The material was then dried and finally heated to about 1050 C. and held there for about 6 hours. The resulting product showed the X-ray diffraction pattern of gamma alumina although the presence of the most prominent beta alumina lines showed that some beta alumina was found. The conversion to beta alumina could be increased by increasing the reaction time. Also it is possible to produce the beta alumina by impregnating the adsorptive starting alumina with an equivalent quantity of alkali metal aluminate and then heating for an extended period at a suitable reaction temperature.

Example III Pellets of a substantially pure activated gamma alumina were impregnated with an aqueous solu- The adsorptive 8 tion of potassium nitrate to incorporate about 19% potassium nitrate. The material was then dried and finally heated to about 1050 C. and held there for about 6 hours. The product was an adsorptive potassium beta alumina.

Example IV A substantially pure commercial activated gamma alumina having approximately the following impurities:

was impregnated with an aqueous solution of sodium nitrate to incorporate the equivalent of about 5.2% NazO. After drying at 200 C. the material was heated at about 910 C. for about 18 hours. Examination by X-ray difiraction showed that only a small amount of the alumina had been converted to beta alumina. The conversion to beta alumina could be increased by raising the reaction temperature, or by increasing the reaction time, or both. Thus, when the reaction time was increased to 36 hours the resulting product was an adsorptive alumina showing the typical X-ray diffraction patterns of beta alumina. The unreacted alkali could be removed by leaching with dilute nitric acid.

The active beta aluminas produced by the method of the invention have catalytic properties similar to the conventional active aluminas hitherto employed as catalysts and exert a similar stabilizing and promoting effect upon the catalytic activities of the catalytic agents customarily employed with alumina. Thus, the adsorptive beta aluminas of the invention may be employed per se as a catalyst in various processes in place of ordinary adsorptive alumina for the reaction of hydrogen sulfide with olefins to produce thiophenic compounds, the dehydration of alcohols, the reforming of Fischer-Tropsch gasoline, the desulfurization of petroleum fractions, the isomerization of olefins and relatedprocesses. For the isomerization of olefins and other processes involving an isomerization the bet-a alumina is, however, improved by impregnating it with an acid, such as sulfamic acid. In some cases the adsorptive beta aluminas of the invention may exhibit a greater catalytic activity, but in general, their superiority over the conventional active aluminas lies in their much greater stability against deactivation due to reversion of the active alumina to inactive alpha alumina. They are especially advantageous therefore in processes where relatively high temperatures (e. g. above 600 F.) and/or steam are encountered. Thus, the active beta alumina catalysts are particularly advantageous in various processes where an organic reactant is contacted with the catalyst under conditions where carbonaceous deposits are formed on the catalytic surface and these deposits are periodically removed by burning. The catalytic reforming, catalytic desulfurization, catalytic cracking and catalytic dehydrogenation of petroleum oils are examples of processes of this kind. In these processes the regeneration of the catalyst by burning the carbonaceous deposits, even when carefully carried out, involves sub- Jecting the catalyst for at least a short time to localized high temperatures and this is one of 9 the prime causes of the deterioration of the catalysts used heretofore in such processes.

While the beta aluminas prepared in microporous form as described may be employed as catalysts per se, their greatest utility will be in multicomponent catalysts. A great numberof inorganiccompounds and some organic compounds are known which are active catalytic promoters and are-used for catalyzing various processes.

tions, the hydration of olefins, and the Fischer- Tropsch synthesis of hydrocarbons The majority of these more active promoters are found among the metals and their compounds. All of these promoters may be applied'with varioussupport-materials such as the hitherto used adsorptive alumina, silica gel, etc.- The adsorptive beta-alumina of the invention .can be advanhitherto employed in suchfcatalysts. A few of the moreuseful catalytic promoters, by way of example are-the metals and their -.compounds, such as their oxides, sulfides halides, chomates, molybdates, tungstates, vanadates, phosphates, borates, and silicates. Examples of these are, for instance, sodium chromate, potassium, dichromate,- silver, silver oxide, silver sulfide, copper, copper oxide, copper sulfide, copper phosphate, calcium molybdate, zinc, zinc oxide, zinc chloride, zinc'sulfide, zinc chromate, cadmium sulfide, barium' chloride, mercuric-chloride, alumininum brov mide, gallium oxide, titanium oxide, zirconium oxide,-tinoxide, tin chloride, lead molybdate, thorium oxide, vanadium oxide, antimony chloride, bismuth oxide; chromium oxide, chromiumsulfide, molybdenum oxide, molybdenumsulflde,

tungsten oxide, tungsten. sulfide, uranium oxide,-

manganese oxide, manganese borate, rhenium' oxide, iron, iron oxide, iron sulfide, iron silicate, cobalt, cobalt oxide, cobalt silicate, cobalt-sulfide,

nickel; nickel oxide, nickel sulfide, nickel'silicate, 3 ruthenium, rhodium, palladium, platinum, and s the'rare earth oxides. Examplesgof other useful sulfamic acid, sulfuricacid, phosphoric acid, sillcotungstic acid and analogous heteropoiy acids.

Other examples of applicablepr'omoters are.

shown, together with suitable methods of incorporation in U. S. Patent No. 2,184,235. While the adsorptive beta alumina of the invention is of generalapplication as a catalyst carrier material and can be employed with any of the conventional catalytic promoters, it is particularly advantageous when it is used in combination with certain types or classes of catalytic promoters which are:

(1) The metals and compounds-of thetransi tion metals, 1. e., those of the transition series of the periodic system of the elements (see J.

Chem. Ed. 21, 532 (1944), and particularly the oxygen and/or sulfur-containing-compounds.

(-2) The metal oxides having a crystallattice isomorphous with alpha alumina;

(3) Metals and metal compound hydrogenation-dehydrogenation catalysts:

, (4) Compounds, Particularly the oxides and l I sulfides of the metals of group VI of the periodic \A system; I

-(5) Metals of groupVIII'of the periodic sys- .tem, particularly ,of the iron group.

It will be noted that these specific groups large- 1y overlap. These various promoters may, of

course, be used invarious combinations, asoften is the practice. a i

The multi-component catalysts containing the SABQM .10 'rialsareused.

drocarbons, the dehydrocyclization of parafiln hy- 5 drocarbons having six or more carbon atoms, the

desulfurization of' sulfur-bearing hydrocarbon fractions, various oxidation processes, various hydrogenation pressures, the amination of olefins, the Deacon process, high temperature chlorinagenated derivatives.

drocarbons such 'as propane, butylene, butane,

pentane, cyclopentane, cyclohexane, methyl 'cyclo tageous substituted for the'adsorptive aluminas hexane, fs-asoline fractions and the like with the catalysts described in detail inU. 8. Patent No.

2,184,235, may be improved by substituting a catalyst prepared from the improved'beta alumina.- When the promoter is molybdenum oxide, the

catalyst is particularly useful for hydroforming.

In hydroforming part of the improvement in 00- tane number is obtained through isomerization. Isomerization is promoted by acid catalysts and 5 is inhibited by alkalis. In the present catalyst 0 alumina, the surface is acidic. In some cases it s is advantageous toinsure an acid surface by: the

incorporation of a small amount of a suitable acid with the promoter. If boric acid is used as the promoter'the catalyst. is useful for effecting cracking of hydrocarbons, the isomerizationof olefins and the transfer of hydrogen from naphthenes to olefins. When silica-tungstic acid is usedJas the promoter the catalyst is good for the hydration of olefins. When the beta alumina car- 40 rier is impregnated with a'surface layer of silica catalytic promoters are, for instance, boric acid, I

-. the resulting multi-component catalyst is a fair cracking catalyst. The adsorptive beta alumina when impregnated with nickel sulfide is an excellent catalyst for selective desulfurization of gasolines-by hydrogenation (for example, as described in U. srPatent No. 2,298,346). By impregnatin'gthe adsorptive beta alumina with cohalt excellent catalysts. for the amination of oleflns and the synthesis of-hydrocarbons by the Fischer Tropsch process maybe prepared. The catalyst resulting whenlthe adsorptive beta alumina is impregnated with aluminum chloride is useful in the isomerization'of'paraffins, but offers no particular advantagein theprocess- 66. The promotermaterial maybe incorporated or combined ;with the adsorptivebetaalumina in-v any of the conventional ways of applying such promoter-materials to active supports. In cases where the promoter material is soluble in water 00. or'another suitable solvent itcan be incorporated on themicroporous surface of the beta alumina by simplysoaking the adsorptive beta alumina with a, solution of the active material and then 1 drying. For example, a catalyst was prepared by soaking an adsorptive beta alumina prepared as described in Example IV and having an available surface of about 123 mfi/g. with an aqueousso lutlon ofcobalt chlorideiCoClrGHzO) to incorporate the equivalent of about 6% cobalt. In

70 other cases it is convenient to impregnate the active beta alumina witha'decomposablc compound of the metal. For instance, catalysts were Thus. by way of example they may '7 be employed in the dehydrogenation of various dehydrogenatable organic compounds, e. 8., hy-

and oxy-- mina.

assess-1 Th(NOa)4'4H2O and then drying and calcining The results are given in the following table:

Material I Heat Treatment Result ted ith sodium oxide alone.... 6 hrs. at 1050 Essentially sodium beta alumina. No alpha alumina. 32:3: al l i a i r g g ated with sodium oxide and "do Algiost completely converted to alpha alumina. No beta id um a. Al li i il p rgono hydrate impregnated with sodium 14 hrs. at 950 C Largely converted to alpha alumina. No beta alumina dichromate. detected.

at 500 C. to decompose the nitrates. This meth- For the reasons indicated it is essential that vanadate, evaporating the-mixture to dryness,

and finally calcining at 500 C. In other cases it is convenient to slurry the powdered active beta alumina in a solution of a compound of the metal, add a precipitant, and then filter and dry the mixture; This is a preferred method for producing catalysts in which fairly large amounts of the catalytic promoters-are-to"beincorporated and has been used very successfully, for exampl -in upwards of preparing cobalt catalysts containing 10% cobalt.

As pointed out, many of the I We claim as our invention:

promoters which catalyze the transformation of gamma alumina to alpha alumina be substantially absent during the reaction to produce the beta alumina. After the beta alumina has been formed,'however, these various promoters may be added. It is preferable in'any casefto incorporate I the desired promoters after the formation of the beta alumina is completedv and .not before. Thus, it is also desirable to employ a substantially pure alumina as the starting material.

1., A process for the preparation of an adsorptive beta alumina suitable for use in catalysis which comprises reacting an alumina of the gamma system of Haber, in the absence of metal oxide'isomorphous with alpha'alumina'with a compound of an alkali metal selected from the group consisting of sodium, potassium and rubidmetal compounds commonly employed as promoters with alumina catalyze the transformation of gamma alumina to alpha alumina; This undesirable property is particularly pronouncedwith promoter material which are isomorphous with alpha-aluminai The oxides of chromium, iron, cobaltand-fmanganese ium -decomposable to the oxide by heat, at a temperature between. about 900 C. and about 1400 C.,for a time ofat least two hours and until thematerial shows the X-ray difiraction patternof beta aluminaof the general formula RzQllAlzOa, .1 R. representing I the alkali metal, the amount of said alkali metal compound em- .ployed being between about. 3, mol and about 12 mol of the alumina.

-2.'IA process for the preparation of an adsorptive beta aluminasuitable for use in catalysls Structure of Crystals," Wykoif-ChemicalCatav gamma alumina+RzO beta alumina, taking place at a. much faster rate than the undesired Also, as pointed out,: a

which comprises activatingan. alumina or the gamma system of Haber to produce a microporous alumina, impregnating the microporous alumina so produced with-a. compound of an alkali metal selected from the g'roup'consisting of sodium, potassium, and rubidium decomposable t5 the oxide by heat, the amount of said alkali metal compound being equivalent 'to between a about 3 mol and about 12 mol of the alkali metal oxide, and reacting the: mixture in I the absence of a metal oxide isomorphous with alpha f alumina at a temperature between about 900 C.

conversion of the gamma alumina to alpha alu- When promoters which catalyze the transformation of gamma alumina to alpha aluminaare present, this reaction tends to take place in preference to the desired conversions to is ilustrated in the following beta alumina. This examples.

Example V impregnated with-chromium oxide (about 9.7%-

A quantity of Alorco Activated Alumina,

Grade A (which is ahighly microporous ac-' tivated alumina of .commerce sold by the Aluminum Ore Company) was impregnated with sodium dichromate (about.5.9% Cr).

and about 1400 C. for a time of at least 3 hours until the product shows the X-ray diffraction pattern of beta. alumina of the general'iormula R20-11A1203.

3. A process for the preparation of an adsorptive beta aumina suitablefor use'in catalysis which comprises reacting an alumina of the gamma system of Haber, in the absence'of metal oxide isomorphous with alpha; alumina, with a compound of an alkali metal selected from the group consisting of sodium, potassium and rubidium decomposable to the oxide byheat, at a temperature between about 900 C.- and about 1400 C.

for a time of at least two hours and until the material shows the X-ray diffraction pattern of beta alumina of the general formula RzOllAlzOa,

The above materials were subjected to heat treatments and then examined by x-ray diffraction.

R representing the alkali metal, the amount of said alkali metal compound employed being between about 3 mol and about 12 mol.-% of the alumina, and thereafter leaching the resulting adsorptive beta alumina substantially free of unreacted alkali.

4. A process for the preparation of an adsorptive beta alumina suitable for use in catalysis which comprises impregnating a microporous alumina of the gamma system of Haber withthe nitrate of an alkali-metal selected from the group consisting of sodium, potassium and rubidium in an amount equivalent to between about 3 mol and about 12 mol 96 of the alkali metal oxide, reacting the mixture at a temperature between about 900 C. and about 1400 C. for a time of at least 2 hours and until the material shows the X-ray diffraction pattern of beta alumina of the general formula R2011AhO:, R

.3 mol and 12 mol of the alkali metal oxides,

heating. the mixture at a temperature between about 900 C. and about1400 C. for aftime of at least'two hours and until the material shows the X-ray diffraction pattern of beta alumina of the general formula RrO-IIAIzOa wherein R represents the alkali metal, and thereafter applying the catalytic promoter to produce the multicomponent catalyst. v

6. In a process for the production of 'amulticomponent alumina-base catalyst wherein a rela-' Haber, in the absence of a metal-oxide isomorphous with alpha alumina, with a compound of 14 a essentially of silioo-tungstic acld supported a preformed surface of beta alumina of the general formula RzO-llAlzOawherein R represents an alkali metal selected from the group consisting of sodium, potassium and rubidium.

11. A preformed multi-component catalyst consisting essentially of metallic nickel supported upon. a preformed surface of beta alumina of the general formula RzO- 11A12O3. wherein R represents an alkali metal selected'from the group consistingof sodium, potassium and rubidium.

12. As a composition of matter-a microporous alumina suitable for use in catalysis prepared by reacting an alumina or the gamma system of an alkali metal selected fromthegroup consisting of sodium, potassium and rubidium decomposable to the oxide by heat, at a temperature be- 'tween about 900 C. and about 1400 C. for a time of at least two hours and until the material shows the Xeray diflractlon pattern of beta alumina of 1 the general formula RiO-llAlaOaR representtively more active catalytic promoter is a plied to an adsorptive alumina carrier the improvement which comprises impregnating the adsorptive alumina with acompoundof an alkali metal selected from the groupconsisting of sodium,

potassium and rubidium convertible to theoxlde: by heat in an amount equivalent to between about 3 mol and 12 mol of the alkali metal oxide, heating the mixtureat a temperaturebetween ing thealkall metal, theamountof said alkali metal compound employed beingbetween about 3 mol and about 12'mol of the alumina,

said alumina having an" available surface of at least 20 mP/g. I

13. As a composition of matter a mioropdrous alumina suitablerfor -use in catalysis prepared by reacting an alumina of the'gamma' system'of Haber,. -in theabsence of a metal' oxide isomerabout 900 C. andabout 1400 C. for a timed at least two hours and .until the material shows the X-ray diffraction pattern of beta alumina of' the general formula 'RzO-llAlaOa wherein R represents the alkali metal, leaching unreacted alkali from the beta alumina so produced, and

thereafter applying the catalytic promoter to produce the multi-component catalyst.

7. A process for the production of an improved catalyst of the type in which a catalytically .active promoter is supported on the surface of an adsorptive support which comprises the combination of steps of depositing anoxide of a .metal selected from the group consisting of sodium, potassium and rubidium in an amount between about 3 mol and 12 mol%, reacting the deposited alkali metal oxide with the alumina. at a temperature above about 900"- C. but below that. causing fusion fora time sufllcient' to convert at least the surface into beta alumina offthe gene;

eral formula R20'11A12o3 wherein R represents the alkali metaLnwashing the resultant product 1 until all free alkali metal oxide is removed, and then incorporating the catalytically active promoter on the said beta. alumina surface.

8. A solidcatalyst composite consisting ,of a cat alytic promoter supported upon a microporous beta alumina-of the general formula R20- llAlzOa wherein R represents a metal selectedfrom the phous withialpha' alumina', -with a.- compound of a sodium decomposable to the oxide. by heat, at a temperature between about 900 C. and about.

1i00f C. for a time of at least two hours and until the material shows the X-ray diffraction pattern of beta alumina ofthe'form'ula NaO-llAlzOa, the amount of .sodium compound employed being between about 3 mol and about 12 mol of "the alumina, said alumina having an available surface of at least 20 mF/g.

14. As a composition of matter a microporous alumina suitable for use in catalysis prepared by .'reacting an-alu mina of the gamma system ,of 'Haber, in the absence of a 'metal' oxide isomorphous with alpha alumina'jwith a compound of a potassium decomposable to the oxide by heat,-

at a temperature between about 900 C. and about 7 1400" C. for a time of at least two hours and until the material shows the x-ray diffraction pattern 5 of beta alumina of the formula K20211A1203, the

amount of potassiumcompound employed being between aboutB mol %'and about 12 mol of the'alumina, said alumina having an available surface of at least .20 mfi/g.

15. As ancomposition of matter a microporous alumina suitable foruse in catalysis prepared by reacting an alumina of the.' gamma system of I Haber, in the absence of a metal oxide isomophous with alpha alumina, with a compound of a rubidium decomposable to the oxide .by heat, at a temperature between about 900 C. and about 1400 C. for a time of at least two hours and until group consisting of sodium, potassium and rubldium, said alumina having an available surface of at least 20 mF/g'. 4

9. A solid multi-component catalyst consisting the material shows the X-ray. diflraction pattern of beta alumina of the formula Rbz0- 11A1zOi, the amount of rubidium compound employed being between about 3 mol and about 12 mol of upon a, preformed surface of beta. alumina of the general formula RaO-llAlzOa wherein R represents an alkali .metal selected from, the group con sisting of sodium, potassium and rubidium. I

' 10. A solid multi-component catalyst consistf ingessentially ofmetallic cobalt supported upon m 16 the alumina, said alumina. having an available UNITED STATES PA'I'ENTS surface of at least 20 mfi/g.

Number Name Date ALBERT E SMITH 2,184,235 GI'OH D80. 19, 1939 OTTO BEECK 2,249,337 Visser et a1. July 15, 1941 2,320,118 Blaker May 25, 1943 REFERENCES CITED The following references are of record in the file of this patent:

OTHER REFERENCES Edwards at 8.1., The Aluminum Industry, vol. 1, page 165. 

